• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.752-755
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• 2003

Injection molding is the one of the most important processes for mass production of plastic parts. Usually Injection molds for mass production are constituted to multi-cavity runner system to manufacture the more parts at a time. To uniformly fill to each cavity, multi-cavity molds are designed to geometrically balanced runner system. However. in practice this is not the case. The previous studies by Beaumount at.[2] reported that filling imbalance occurred by thermal unbalance on the mold and viscosity variation of resins and so on. In this study, we conducted experiments in order to know the causes or filling imbalance for 3 plate type mold with 8 cavities. We presented a new so called 4BF mold(4plate Type Balanced Filling Mold) to improve filling balance. We conducted a experimental injection molding to verify a efficiency of the 4BF mold. In the results of the experiment, We could confirmed the possibility of the 4BF mold.

• Design & Manufacturing
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• v.2 no.6
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• pp.33-37
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• 2008

Almost all injection molds have multi-cavity, which are designed with geometrically balanced runner system in order to made filling balance between cavity to cavity during injection molding. However, filling imbalance has been existed in the geometrically balanced runner system. In this study, we made an experiment and investigated that are filling balanced according to material. Also, in case of filling imbalance was occurred, we conducted experiments in order to find out difference of cavity pressure with cavity pressure sensor. When filling imbalance was occurred between cavity to cavity, we investigated the filling imbalance and pressure differences by computer-aided engineering(CAE).

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.381-388
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• 2003

The paper presents our study of development for multi-cavity preform mold system which consists of hot runner system and valve gate. For this purpose, stretching blow molding process and preform injection process were simulated by Polyflow and Moldflow. Based on various results of the preform injection process analysis, process planning was established. The sectional thickness distribution of preform was optimized. Preform injection mold system was designed by these technical analysis data. Finally, 24-cavity preform mold system was successfully developed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.266-270
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• 2007

Small injection molded articles such as lens and mobile product's parts are usually molded in multi-cavity mold. The problems occurred in multi-cavity molding are flow imbalance among the cavities. The flow imbalance affects on the dimensions and physical properties of molded articles. First of all, the origin of flow imbalance is geometrical imbalance of delivery system. However, even the geometry of delivery system is balanced well the cavity imbalance is being developed. This comes from the unsuitable operational conditions of injection molding. Among the operational conditions, injection speed is the most significant process variable affecting the filling imbalances in multi-cavity injection molding. In this study, experimental study of flow imbalance has been conducted for various injection speeds and materials. Also, the filling Imbalances were compared with CAE results. The dimensions and physical state of multi-cavity molded parts were examined. The results showed that the filling imbalances vary according to the injection speed and flow property of resins. Subsequently, the imbalanced filling and pressure distribution in the multi-cavity affect on the dimensions and physical states of molded parts.

• Design & Manufacturing
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• v.8 no.2
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• pp.41-45
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• 2014

Automated polishing apparatus based on the research have been developed. The research is improvement of polishing process for surface quality and uniformity improvement of preform injection mold core. Surface quality of preform core have influence on ejecting and product quality after injection molding. Thus, the current being made by hand to automate the polishing process, the surface of the preform to improve the quality and uniformity improvement. First made a division by analyzing manual process a step-by-step. And draw a mechanism for converting mechanical movement. Automated polishing apparatus for preform core was developed, through which shortens production time and were able to secure the safety of the worker.

• Transactions of Materials Processing
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• v.15 no.1 s.82
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• pp.42-46
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• 2006

For mass production, usually injection mold has multi-cavity which is filled through geometrical balanced runner system. Despite geometrical balanced runner system, filling imbalances between cavity to cavity have always been observed. These filling imbalances are one of the most significant factors to affect quality of plastic parts. Filling imbalances are results from non-symmetrical shear rate distribution within melt when it flows through tile runner system. It has been possible to decrease filling imbalance by optimizing processing conditions, but it has not completely eliminated this phenomenon during injection molding processing. This paper presents a solution for these filling imbalances by using Runner Core pin (RC pin). The Runner Core pin which is developed in this study creates a symmetrical shear distribution within runner. As a result of using Runner Core pin, a remarkable improvement in reducing filling imbalances was confirmed.

• Design & Manufacturing
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• v.17 no.4
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• pp.57-62
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• 2023

As a representative method for mass production, a multi-cavity type mold capable of simultaneously molding products of the same shape can be applied. It has the advantage of improving the productivity from several times to several tens of times, but it may cause disadvantages which is the quality deviation with each cavity. This study, therefore, has tried to increase the cavity filling balance by using a melt flipper and a flow distance control part in the runner part of the mold. Along with this, the design and manufacturing of air vents during injection molding have been verified through experimental methods to achieve a higher level of multi-cavity filling balance and dimensional accuracy.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.9 s.174
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• pp.173-178
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• 2005

Recently plastic parts are molded for the purpose of mass production in multi-cavity system. Therefore, designer is usually designing mold that has geometrically balanced runner lay-out for filling balance at each cavity. Although, mold is manufactured with geometrically balanced runner lay-out, there are actually filling imbalances in the cavities. These filling imbalances phenomenon are caused by complicated interaction between melt and mold. In this study, based on previous studies for filling imbalances in cold-runner mold, filling imbalances in hot-runner mold were investigated by CAE and injection molding experiments. ABS and PMMA as amorphous polymer, PA as crystalline polymer were used to compare the filling imbalances. There were different results of CAE and experiment. The filling imbalances decreased as injection rate increased without regard to kind of resins and were lower than the one of cold-runner.

• Design & Manufacturing
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• v.2 no.5
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• pp.16-20
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• 2008

Almost all injection molds have multi-cavity runner system for mass production, which are designed with geometrically balanced runner system in order to accomplish filling balance between cavity to cavity during processing; However, even though geometrically balanced runner is used, filling imbalances have been observed. In these day, the CAE has been used widely in injection molding. However, CAE with fusion mesh can't indicate such as jetting, flow mark and filling imbalance in multi cavity mold. In this study, we investigated the filling imbalance according to runner shapes by CAE analysis. As a result in CAE, in case of binary branch runner system, filling imbalance was indicated between cavity to cavity, but the flow pattern of each cavity uniformed in unary branch runner system.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.10a
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• pp.54-57
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• 2004

Almost all injection molds have multi-cavity runner for mass production, which are designed with geometrically balanced runner system in order to minimize filling imbalance between cavity to cavity during processing. However, even though geometrically balanced runner is used, filling imbalances have sometimes been observed. These filling imbalances have historically been considered as result of uneven mold temperature and mold deflection, but it actually results from non-symmetrically shear, pressure, temperature distribution within melt material as it flows through the runner system. Filling imbalance could be decreased by modifying processing conditions that are related to shear, pressure, temperature such as injection rate, mold temperature, injection pressure, melt temperature. In this study, a series of experiment was conducted using Taguchi method to determine which processing condition influence as the primary cause of filling imbalance in geometrically balanced runner system. As a result of experiments, this paper could present an optimal processing condition to minimize variable that brings about filling imbalance geometrically balanced runner system